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Old 02-04-14, 08:25 PM   #341
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Default Re: Project: Garage Find

Is it the switch itself? Put a normal bolt in and see if you still get a leak.

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Old 02-04-14, 08:26 PM   #342
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Default Re: Project: Garage Find

Got a picture of the offending area?

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Old 02-04-14, 08:27 PM   #343
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Default Re: Project: Garage Find

The switch looks good. Cant see any damage to it. But yep that's worth trying. Will have to see if I have a bolt of the right size.

Any other ideas?
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Old 02-04-14, 08:39 PM   #344
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Default Re: Project: Garage Find

Its not an easy thing to photograph, but this is the area when the engine was out if the frame:



And this is the bolt before it went in:

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Old 02-04-14, 09:17 PM   #345
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Default Re: Project: Garage Find

Some more pictures:



As you look at the switch you should be able to see a little glistening of oil on the right. There is not much there at the moment but it is there for sure. And that is only with the oil being in for an hour or two.



Not sure if its any help, but that is the bolt from the side/ underneath. The extra gasket is the bit that was on my finger that I didn't notice yesterday and cleaning it up didn't really work.
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Old 02-04-14, 10:07 PM   #346
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Default Re: Project: Garage Find

Could you not try a bit of plumbers PTFE tape on the threads. It should defo be ok with the heat, the oil..............might be worth a go!
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Old 02-04-14, 11:41 PM   #347
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Default Re: Project: Garage Find

Not sure about PTFE from what I've seen it will bunch at the head and this needs a good seal. However that has me thinking...

Unless someone thinks this is a bad idea, would using instant gasket on the threads and the sealing faces of the copper washer torqued up be worth a shot?
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Old 03-04-14, 08:18 AM   #348
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Default Re: Project: Garage Find

Check the face where the washer seals on the case, and the same on the switch, as you know there is no pressure in the gearbox so for there to be a leak it's not so much that the seal doesn't, there must actually be a mismatch between the two pieces that touch - a gap, however small - as the oil is relatively viscous, and there is no great 'head of water' above the seal area. Remove the washer and refit the switch, do the bits actually mate, and if not, which is not flat? I'm not familiar with that exact engine, (although I suspect it's typical Yamaha tech of the era), would it be possible to wrap the switch threads in PTFE or perhaps seal the threads directly with a gasket paste/silicone?
Last thing, are you sure the leak is not through the switch itself, rather than around the outside?
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Old 03-04-14, 08:50 AM   #349
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Default Re: Project: Garage Find

All good options, i'd go with the ptfe tape first, then if that does not work, using instant gasket on the threads.
As has also been said, a bolt of the right size to test if its the threads on the neutral switch. Something definitely is not right.
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Old 03-04-14, 09:19 AM   #350
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Default Re: Project: Garage Find

My freind that races tzrs and has some road tzrs and tdrs suggested perhaps a fibre washer is meant to be used?
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